Custom full box build pcb assembly

Wet tag production wasn’t something we’ve ever done before, here at MPE.

Equipped with our ‘can-do’ approach and mantra to prioritise client needs, our expert team, led by our Production Manager Paul Owen, leveraged their skills and industry experience to successfully rise to the challenge.

Read on for details about how we designed, set up and now consistently run a full box build wet tag assembly line with the capacity to produce 900 plus wet tag units per month for one of our key clients, a global tyre manufacturer.

Mitigating supply chain disruption and human risk

As our client faced increasing demand from their customers to utilise wet tag sensors in their products, they needed to find and secure a dependable PCB supplier.

With rising scrutiny of and strict safety regulation in the mining industry, our client is under pressure to find ever more efficient and effective ways to ensure the safety of their tyre products. Should essential components, such as wet tags fail, the risk to their client relationship, as well as their clients’ employees’ personal safety on mine sites would be seriously compromised. Appointing a preferred supplier, able to produce wet tags to a consistently high quality standard, would be crucial to their future success.

Already working with the original designer of the wet tag technology RVL, (who was at the time the sole manufacturer), our client sought a second supplier to spread the potential risk of wet tag supply chain disruption.

Can-Do’ approach

Based on our existing relationship, the client decided to partner directly with MPE for the production of the wet tags, choosing not to consider any other potential suppliers.

We immediately ran a feasibility study. Our team always adopts a ‘can-do’ approach to meeting individual client requirements. But, what we endeavour to deliver is backed up with careful planning and preparation, which is deeply rooted in our internal governance and controls. This ensures we continue to deliver to the high standard expected of us.

Our feasibility study explored space, build, equipment, processes and training from both a quality assurance and safety perspective. Once we were certain we could deliver a full box build wet tag assembly service based on these criteria, we could move ahead with the development of the manufacturing facility and the assembly line.

Our response

We place great importance on meticulously interpreting the product datasheet. We needed to establish what we could set up and produce ourselves, as well as what we needed to outsource.

Wet tag production depends heavily on using ceramic boards instead of the traditional fibreglass boards. Ceramic boards aren’t porous and won’t absorb the oil used in wet tag technology. Ceramic boards are only produced by specialist manufacturers. Knowing this, we secured an experienced supplier to provide the ceramic boards, so that we could focus on the rest of the wet tag production.

Next, we needed to consider manufacturing space. We had to guarantee enough physical space to maximise the operation of the assembly line itself. We also required room for other elements of the process, such as storage of the oil used in wet tag production. We moved all of our existing client PCB assembly to our main manufacturing facility, to reserve our secondary plant for the sole production of the wet tags.

Equipment was another major factor in determining the success of the operation. Testing equipment, specifically radio frequency testing, antenna tuning and pressure testing, as well as the oil filling machine, and additional equipment used in the wet tag cleaning process, had to be securely installed to support optimal production.

Due to detailed planning, we were able to set up our very first wet tag assembly line in the new facility within eight months.

Foresight and planning to overcome issues

After analysing the wet tag product datasheet, we understood that the cleaning solvent required to clean the oil must not enter the drainage system. Therefore, we installed a waste tank, into which the water/solvent/oil mix is drained. In order to ensure that the tank is tamper-proof, the tank is housed in a locked metal bunded cabinet. This also prevents spillage or leaks escaping into the surrounding environment. Having found this solution, we then had to seek approval from the landlord to allow us to place the cabinet outside the factory unit.

Initially, our team was unfamiliar with oil filling; we simply hadn’t done this before. Having carefully assembled a talented and experienced team over many years, and arranging for specialist training, we were confident we could deliver.

Fast results

By the end of our first month, we produced 300 units, and in October we produced 600. We have the capacity to produce 900 plus a month. We’ve also received positive results from a recent two-day audit our client carried out, which included an in-depth examination of our processes, the product itself, our set-up, management and documentation, and ability to control our supply chain.